Mechanic's Tips 3000 and 4000 Product Families

1 MT3004 ENMechanic s Tips3000 and 4000 Product FamiliesAllison TransmissionAllison WTEC III Controls(Except 3000 Product Family 7-Speed)Mechanic sTips2006 MARCHMT3004EN3000 Product Family4000 Product FamilyPrinted in USAC opyright 2007 Allison Transmission, Transmission, Box 894 Indianapolis, Indiana 46206-0894ww OF CONTENTSSECTION I INTRODUCTION1 1 ABOUT THIS 7 SECTION II PREVENTIVE MAINTENANCE2 1 PERIODIC INSPECTION AND 202 2 IMPORTANCE OF PROPER TRANSMISSION FLUID 202 3 TRANSMISSION FLUID 212 4 KEEPING FLUID 272 6 TRANSMISSION FLUID AND FILTER CHANGE 282 7 TRANSMISSION FLUID 322 8 TRANSMISSION FLUID AND FILTER CHANGE 352 9 FLUID LEAK 372 10 402 11 402 12 TRANSMISSION STALL TEST AND NEUTRAL 45 SECTION III REMOVING TRANSMISSION3 1 DRAINING 513 2 DISCONNECTING 513 3 UNCOUPLING FROM DRIVELINE, ENGINE.

2 AND 523 4 REMOVING THE 533 5 REMOVING OUTPUT FLANGE OR 53 SECTION IV TRANSMISSION PREPARATION4 1 INSPECTING INPUT 554 2 INSTALLING OUTPUT FLANGE OR 554 3 INSTALLING 564 4 INSTALLING FILL TUBE AND 574 5 INSPECTING PLUGS AND 583 SECTION V PREPARING VEHICLE FOR TRANSMISSIONINSTALLATION5 1 ENGINE, TRANSMISSION ADAPTATION 595 2 CHECKING FLEXPLATE DRIVE 625 3 CHASSIS AND DRIVELINE 635 4 COOLER, FILTER, AND 645 5 INSPECTING 65 SECTION VI INSTALLING TRANSMISSION INTO VEHICLE6 1 696 2 MOUNTING TO 696 3 INSTALLING TRANSMISSION MOUNTING 706 4 COUPLING TO 706 5 CONNECTING OUTPUT RETARDER 706 6 CONNECTING POWER TAKEOFF 716 7 CONNECTING PARKING BRAKE 726 8 CONNECTING 726 9 CONNECTING ELECTRICAL 726 10 CONNECTING SPEEDOMETER 746 11 FILLING HYDRAULIC 756 12 INSTALLATION INSPECTION 75 SECTION VII INSPECTIONS AND ADJUSTMENTS7 1 INSTALLATION INSPECTION 767 2 ROAD TEST AND VEHICLE OPERATION INSPECTION 78 SECTION VIII CUSTOMER

3 SERVICE8 1 OWNER 808 2 SERVICE 804 TRADEMARK USAGEThe following trademarks are the property of the companies indicated: Allison DOC is a trademark of General Motors Corporation. DEXRON is a registered trademark of the General Motors Corporation. TranSynd is a trademark of Castrol Ltd. LPS Electro Contact Cleaner is a registered trademark of , CAUTIONS, NOTESIT IS YOUR RESPONSIBILITYto be completely familiar with the warningsand cautions described in this handbook. It is, however, important to understandthat these warnings and cautions are not exhaustive. Allison Transmission couldnot possibly know, evaluate, and advise the service trade of all conceivable waysin which service might be done or of the possible hazardous consequences of eachway.

4 The vehicle manufacturer is responsible for providing information related tothe operation of vehicle systems (including appropriate warnings, cautions, andnotes). Consequently, Allison Transmission has not undertaken any such broadevaluation. Accordingly, ANYONE WHO USES A SERVICE PROCEDURE ORTOOL WHICH IS NOT RECOMMENDED BY ALLISON TRANSMISSION ORTHE VEHICLE MANUFACTURER MUST first be thoroughly satisfied thatneither personal safety nor equipment safety will be jeopardized by the servicemethods service and repair is important to the safe, reliable operation of theequipment. The service procedures recommended by Allison Transmission (or thevehicle manufacturer) and described in this handbook are effective methods forperforming service operations.

5 Some of these service operations require the use oftools specially designed for the purpose. The special tools should be used whenand as following three types of headings are used in this manual to attract :A warning is used when an operating procedure, practice,etc., if not correctly followed, could result in personal injury or loss :A caution is used when an operating procedure, practice,etc., if not strictly observed, could result in damage to or destruction :A note is used when an operating procedure, practice, etc., isessential to 1. ABOUT THIS MANUALThis handbook is a mechanic s reference for maintaining, removing, or installingthe 3000 and 4000 Product Families on-highway transmission with a WTEC IIIcontrol system.

6 WTEC III controls were optional on the 3000 and 4000 ProductFamilies on-highway transmission units built in 1997, but became standard onunits built starting in features of the transmission and the vehicle involved in installation proceduresare discussed. The information presented will help the mechanic maintain, remove,or install the transmission in a manner that promotes satisfactory operation andlong service life. For additional detailed information, refer to the appropriatetransmission service manual and electronic controls troubleshooting specifically indicated otherwise, this handbook refers to all 3000 and 4000 Product Families on-highway transmissions, except 7-speed models.

7 Thedifferences between the various transmissions are explained as LEVEL SENSORP2 MODULEP1 MODULECONVERTER MODULE TURBINE PUMP LOCKUP CLUTCH/DAMPER STATORCONVERTER HOUSING MODULE CONVERTER HOUSING PTO DRIVE GEARROTATING CLUTCH MODULE C1 CLUTCH C2 CLUTCH TURBINE SHAFT CONTROL MODULE ELECTRO-HYDRAULIC CONTROLSMAIN SHAFT MODULE MAIN SHAFT P2 SUN P3 SUNMAIN HOUSING MODULE MAIN HOUSING C3 CLUTCH C4 CLUTCH C5 CLUTCHFRONT SUPPORT/OIL PUMP MODULE FRONT SUPPORT OIL PUMPREAR COVER MODULE OUTPUT SHAFT P3 C5 PISTONF igure 1 1. 3000 Product Family Transmissionwith PTO Cross Section8 ROTATING CLUTCH MODULE C1 CLUTCH C2 CLUTCH TURBINE SHAFT CONTROL MODULE ELECTRO-HYDRAULIC CONTROLSP1 MODULEP2 MODULEMAIN HOUSING MODULE MAIN HOUSING C3 CLUTCH C4 CLUTCH C5 CLUTCHMAIN SHAFT MODULE MAIN SHAFT P2 SUN P3 SUNREAR COVER MODULE OUTPUT SHAFT P3 MODULE C5 MODULETURBINEPUMPSTATORLOCKUPCLUTCH/DAMP ERCONVERTER HOUSING MODULECONVERTER HOUSINGFRONT SUPPORT/OIL PUMP MODULEFRONT SUPPORT OIL PUMPF igure 1 2.

8 3000 Product Family Transmission Cross HOUSING MODULE MAIN HOUSING C3 CLUTCH C4 CLUTCH C5 CLUTCHROTATING CLUTCH MODULE C1 CLUTCH C2 CLUTCH TURBINE SHAFT CONTROL MODULE ELECTRO-HYDRAULIC CONTROLSP3 MODULEP2 MODULEP1 MODULEMAIN SHAFT MODULE MAIN SHAFT P2 SUN P3 SUNRETARDER MODULE STATOR ASSEMBLY ROTOR HOUSING ASSEMBLYCONVERTER HOUSING MODULECONVERTER HOUSINGFRONT SUPPORT/OIL PUMP MODULEFRONT SUPPORT OIL PUMPCONVERTER MODULETURBINEPUMPSTATORLOCKUPCLUTCH/DAMP ERF igure 1 3. 4000 Product Family Transmissionwith Retarder Cross HOUSING MODULE MAIN HOUSING C3 CLUTCH C4 CLUTCH C5 CLUTCHROTATING CLUTCH MODULE C1 CLUTCH C2 CLUTCH TURBINE SHAFT CONTROL MODULE ELECTRO-HYDRAULIC CONTROLSP2 MODULEP1 MODULEMAIN SHAFT MODULE MAIN SHAFT P2 SUN P3 SUNREAR COVER MODULE OUTPUT SHAFT P3 MODULE C5 PISTONCONVERTER HOUSING MODULECONVERTER HOUSINGPTO DRIVE GEAR FRONT SUPPORT/OIL PUMP MODULEFRONT SUPPORT OIL PUMPCONVERTER MODULETURBINEPUMPSTATORLOCKUPCLUTCH/DAMP ERF igure 1 4.

9 4000 Product Family Transmissionwith PTO Cross PMUP ROTATS PUKCOL /HCTULCREPMAD PMUP LIO TROPPUS TNORF ELUDOM PMUP LIO/TROPPUS TNORFGNISUOH NIAM HCTULC 3C HCTULC 4C HCTULC 5C ELUDOM GNISUOH NIAMELUDOM RETREVNOCTFAHS ENIBRUT HCTULC 1C HCTULC 2C ELUDOM HCTULC GNITATOR GNISUOH RETREVNOCRETREVNOCELUDOM GNISUOH TFAHS NIAMNUS 3P NUS 2P TFAHS NIAMELUDOMELUDOM 3 PELUDOM 2 PELUDOM 1 PGNISUOH RETPADA 6C HCTULC 6 CELUDOM 4P GNISUOH RETPADA 6 CELUDOM REVOC RAER TFAHS TUPTUOREVOC RAERELUDOMF igure 1 5. 4000 Product Family Transmission7-Speed Cross Section12 PTOPROVISIONOUTPUTSPEEDSENSORNAMEPLATERI GHT-REAR VIEWLEFT-FRONT VIEWINPUTSPEEDSENSORASSEMBLY PADSMAIN-PRESSURE TAPNOTE: Inch series ThreadsBREATHERFEEDTHROUGH HARNESSCONNECTORCOOLER PORTSNOTE: Inch series PADS(BOTH SIDES)BREATHERMAIN-PRESSURE TAPNOTE: Inch series ThreadsFEEDTHROUGH HARNESSCONNECTORTORQUE CONVERTERWITH LOCKUP CLUTCHAND TORSIONAL DAMPERPTO PROVISION(AVAILABLE BOTH SIDES)Figure 1 6.

10 3000 Product Family Transmission with PTO13 ASSEMBLY PADS(BOTH SIDES)TO RETARDERACCUMULATOROIL FILL TUBE ANDDIPSTICK(AVAILABLE ONBOTH SIDES)OUTPUT RETARDERTORQUE CONVERTERWITH LOCKUP CLUTCHAND TORSIONAL DAMPERBREATHERMAIN-PRESSURE TAPNOTE: Inch series threadsFEEDTHROUGHHARNESSCONNECTORINPUT SPEEDSENSORNAMEPLATEASSEMBLY PADSMAIN-PRESSURE TAPNOTE: Inch series ThreadsBREATHERCOOLER PORTSNOTE: Inch series ThreadsRIGHT-REAR VIEWLEFT-FRONT 1 7. 3000 Product Family Transmission with Retarder14 ASSEMBLY PADS(BOTH SIDES)TO RETARDERACCUMULATOROIL FILL TUBEAND DIPSTICK(AVAILABLE ONBOTH SIDES)OUTPUT RETARDERTORQUE CONVERTERWITH LOCKUP CLUTCHAND TORSIONAL DAMPERBREATHERMAIN-PRESSURE TAPNOTE: Inch series threadsFEEDTHROUGHHARNESSCONNECTORRETARD ERVALVE BODYCONNECTOROUTPUTSPEEDSENSORASSEMBLY PADSMAIN-PRESSURE TAPNOTE: Inch series ThreadsBREATHERCOOLER PORTSNOTE: Inch series ThreadsLEFT-REAR VIEWLEFT-FRONT PROVISIONNOTE: Metric series ThreadsS